pdi

PLASTIC
DRUM
INSTITUTE

Plastic Drum Paneling Issues

 PANELING

BACKGROUND

This report will explain the causes of paneling and suggest some possible ways
to eliminate or minimize the paneling of plastic drums.

Drums are relatively thin walled packages whether they are steel, fiber or plastic.
They are not intended to be pressure vessels. However, in some industrial
applications they are subjected to pressure influences both internal and external.
In many cases, the pressures exerted are within the tolerances acceptable for
that package. When the pressures exerted on the package are outside the
acceptable tolerance ranges, a distortion may be seen in the outer surface of the
package. This phenomenon is usually referred to as paneling.

CAUSES OF CONTAINER PANELING

1. Changes in the temperature of the lading being packaged

2. Permeation of the lading into the wall of the container

3. Storage of an oxygen scavenger lading in the container

4. Changes in atmospheric pressure conditions

A container panels because the pressure inside the drum has become
significantly less than the pressure outside the drum. All of the above
reasons for the paneling of containers have this same effect – they change the
pressure differential across the container. The question then is, ‘how much
pressure difference is too much?’ The results of the following Paneling Test for
Plastic Containers provide the answers on a case-by-case basis.

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SUMMARY

The problem of paneling has three possible causes: the temperature differential
across the container is too great, the lading being package is a strong permeator,
or the lading being packaged is a strong oxygen scavenger. A significant
increase in atmospheric pressure (relative to the atmospheric pressure when the
container was initially sealed) can cause a package that is relatively stressed
near the point of paneling (by some other cause) to actually begin to panel.

All of the causes of paneling have solutions. If a temperature difference is

causing the problem, use the results provided in the paneling test to determine a
maximum temperature range for your container and either allow sufficient time
for the lading to cool to an acceptable temperature or utilize plugs with venting
systems in your containers. If you suspect a compatibility problem between your
Lading and the container, please speak with your polyethylene material supplier.
They can have your lading tested according to the DOT procedures provided in
this report. A problem with oxygen scavenging is easily remedied by placing a
blanket of nitrogen gas over the liquid being packaged.

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PANELING TEST FOR PLASTIC CONTAINERS

TEST PURPOSE AND SCOPE:

The purpose of this test is to determine the amount of vacuum a given container
can sustain before paneling occurs. Each type of container will be tested both
empty and filled with water.

Equipment List:

Quincy air compressor Model QSI – 235

McDaniel Controls vacuum gauge (0 to 30 inch HG full scale)
Norgren air pressure regulator Model 11-018-100
Festo vacuum generator type VAD – 3/8

TEST PROCEDURE:

1. Perform this test at ambient conditions (c. 70 °F).

2. Obtain two samples of each type of container. Fill one of the samples with
water to about five inches below the bung opening.

3. Plug the bung opening of the drum, as necessary. Using a punched out 2
in. NPT plug, attach the test apparatus to the drum. Connect the
compressor air line to the test apparatus and set the initial vacuum to 1
inch HG using the pressure regulator

4. Once the vacuum in the drum reaches 1 inch of Hg, wait for two minutes.
This will allow time for the sidewall of the drum to relax and adjust to the
new pressure.

5. Using the pressure regulator, increase the vacuum in the drum by 0.25
inch Hg and again allow 2 minutes to pass.

6. Repeat Step 5 until the head of the drum draws in and record the
pressure.

7. Continue to repeat Step 5 until paneling begins to occur and record this
pressure.

8. Detach the compressor airline from the test apparatus and allow the
vacuum in the drum to reach ZERO. Remove the test apparatus from the
drum.

9. Repeat STEPS 3 through 8 for all containers that are to be tested.

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RESULTS AND OBSERVATIONS

A filled container will always withstand a greater vacuum than an empty one
because the lading places outward pressure on the container sidewall. This
outward pressure counteracts a part of the vacuum applied to the container.

Once a given container begins to panel, it will continue to panel until the amount
of the vacuum in the container decreases by approx. 0.5 psi. This reduction in
vacuum normally occurs as the container walls panel. Paneling reduces the
volume of the container and as a result, the vacuum inside the container. This
means that a container will only panel to a limited degree, that is, until the
vacuum inside the container drops just enough that paneling can no longer occur
(in most cases this is approx. 0.5 psi). However, in this test we held a constant
vacuum on the test container. This caused the container to continue to panel
until severe distortion of the sidewall occurred. Also, once a container sidewall
has buckled due to paneling, it will require less vacuum to cause the container to
panel again. The reduction in paneling pressure is proportional to the severity of
the previous paneling incident.

The paneling pressure is also dependent on the temperatures of the container’s

sidewall: if the container is hot, the sidewall is more ductile and will deform more
easily.

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PANELING DUE TO A TEMPERATURE DIFFERENTIAL

The following table and graph show the amount of vacuum induced within a drum
as a function of the temperature differential between the drum’s contents and
surroundings (or inside and outside). This graph can be used in combination
with the results from the paneling test to predict if a drum will panel given the
temperature differential across the drum.

This cause of paneling can be eliminated in one of 4 ways.

1. Allow lading to cool longer before filling the container. (Using the results
of the paneling test, one can determine a maximum temperature
differential for a given container and calculate the maximum allowable
temperature for the lading being packaged.

2. Allow lading to cool longer after filling but before sealing.

3. Do not store the packaged goods in a location that is cooler than the filling
temperature by an amount exceeding the maximum temperatures.

4. Utilize a venting system.

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VACUUM Vs. TEMPERATURE DIFFERENTIAL

Temperature (°F) Vacuum (psig)

1 0.184
2 0.368
3 0.552
4 0.736
5 0.92
6 1.104
7 1.288
8 1.472
9 1.656
10 1.84
11 2.024
12 2.208
13 2.392
14 2.576
15 2.76
16 2.944
17 3.128
18 3.312
19 3.496
20 3.68
21 3.864
22 4.048
23 4.232
24 4.416
25 4.6
26 4.784
27 4.968
28 5.152
29 5.336
30 5.52
31 5.704
32 5.888
33 6.072
34 6.256
35 6.44
36 6.624
37 6.808
38 6.992
39 7.176
40 7.36
41 7.544
42 7.728

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 Panel Effect (Vacuum Induced vs. Temperature Differential)

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Vacuum (psig)

0
11

13

15

17

19

21

23

25

27

29

31

33

35

37

39

41
1

Temperature (°F)
PANELING DUE TO STRONG PERMEATORS

Paneling can be caused by a chemical incompatibility between the lading and the
container. The result is permeation of the lading into the walls of the container.
This reduces the pressure inside the container and cause paneling. The
Department of Transportation has a specific test to determine the compatibility of
liquid materials packaged in plastic containers. A copy of the test is included on
the next page.

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D.O.T. PROCEDURE FOR TESTING CHEMICAL COMPATIBILITY AND RATE
OF PERMEATION IN PLASTIC PACKAGING AND RECEPTACLES

Appendix B to Part 173

1. The purpose of this procedure is to determine the chemical compatibility

and permeability of liquid hazardous materials packaged in plastic
packaging and receptacles. Alternatives for this procedure are permitted
as specified in part 173.24 (e) (3) (iii) of this subchapter.
2. Compatibility and rate of permeation are determined by subjecting full size
plastic containers (or smaller containers as permitted in paragraph 4 of
this Appendix) and hazardous material lading to Test Method 2: 28 days at
a temperature no lower than 50 °C (122 °F).
3. At least three sample containers shall be tested for each combination of
hazardous material and size and design of container. Fill the containers to
rated capacity with the specific hazardous material (at the concentration to
be transported) and close as for shipment. For the first and last 24 hours
of storage, place the containers with closures pointed downward, except
that containers fitted with a vent are so placed on each occasion for five
minutes only.
4. In those instances where it is not practicable to use full size containers,
smaller containers may be used. The smaller container shall be
manufactured by the same process as the larger container (e.g. using the
same method of molding and processing temperatures) and be made of
identical resins, pigments and additives.
5. Determine filled container weight or net weight of contents both before and
after storage. Rate of permeation is determined from loss of hazardous
materials contents, during the test exposure time, expressed as a
percentage of the original weight.
6. After storage, the container shall be drained, rinsed, filled to rated capacity
with water at ambient temperature, dropped from a height determined in
accordance with part 178.603 (d) of this subchapter onto a rigid non-
resilient, flat and horizontal surface.
7. Each of the following constitute test failure:
a. Visible evidence of permanent deformation due to vapor pressure
build-up or collapse of walls, deterioration, swelling, crazing, cracking,
excessive corrosion, oxidation, embrittlement, leakage, rupture or other
defects likely to cause premature failure or a hazardous condition.
b. For materials meeting the definition of a poison according to this
subchapter, a rate of permeation in excess of 0.5 % determined over
the test period. For all other hazardous materials, a rate of permeation
in excess of 2.0% determined over the test period.

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PANELING DUE TO OXYGEN SCAVENGERS

Another cause of paneling is storage of goods that deplete the oxygen inside the
container. These types of liquids react with and consume the oxygen in the
airspace between the liquid and the head of the container. As this occurs, the air
pressure inside the container drops (due to loss of the oxygen into the liquid) and
the container may panel. A simple solution to this problem is to displace the air
above the liquid with a heavier inert gas (such as nitrogen), before sealing the
container.

PANELING DUE TO PRODUCT ABSORPTION

Product absorption occurs from the inside of the drum in contact with the lading
and generally will be present as a gradient across the wall thickness. Depending
on the products tendency to cause swelling of the Polyethylene there will be a
differential growth across the thickness resulting in the inner layer growing faster
than the outer layers. Since the expansion is non-uniform across the wall inward
deformation or paneling will take place to relieve the stress. Products that cause
this effect are typically those similar to Polyethylene, e.g. Hydrocarbons, and do
not evaporate from the exterior surface at an appreciable rate so there is no
observed "permeation" loss.

PANELING DUE TO PRESSURE CHANGES

Paneling can occur due to change in atmospheric pressure. As noted above it

does not take a large pressure difference to cause paneling. An increase in
barometric pressure from time of filling can be enough to result in paneling.
Another cause is a change in pressure due to altitude changes. For example a
drum filled in Denver and shipped to Los Angeles would experience an increase
in external pressure of about 2.5 psi, 5000 ft. to 0 feet altitude. See graph.

Pressure vsa. Altitude

16.00
15.00
Pressure - PSI

14.00
13.00
12.00
11.00
10.00
9.00
0 2000 4000 6000 8000 10000 12000
Altitude - feet

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Paneling caused by any of the factors described above can be seen on drums
anywhere in a storage situation e.g. any tier of a stacked array. Apparent
paneling appearing only in the bottom layer of a stack is usually the result of poor
stacking conditions. Most UN 1H1 drums are stack tested to a specific gravity of
1.8 or 1.9 meaning they were subjected to a top load of 2100 or 2300 pounds for
28 days at 40 ºC. In many cases observable deformation is reported in much
shorter times and lower temperatures at lower top loading. In these cases the
collapse is due mainly to point loading resulting from the use of poor pallet
designs. Namely, pallets that are designed to be used with steel drums or other
types of packagings do not support a plastic drum adequately. In a stack test the
force is applied uniformly to the drums between parallel, usually steel, platens on
a level surface. In practice the pallets used e.g. a 46" x 46" has three stringers
and only three to five bottom deck boards and seven top deck boards. The
stringers are typically on 22" centers so that they are out the outer edge of a
drum with a 22.5" OD and therefore results in point loading. Collapse can be
seen below the point of contact with the drum as shown in the photo. The deck
boards can also sag and apply non-uniform loading to the drums. Another factor
is the surface where stacks are stored. In many warehouses floors are slightly
sloped to allow for drainage in case of spills. This can cause a slight tilt in a stack
and shift the load to one side of a stack. The use of vented closures will also
reduce the ability of a plastic drum to support a load. This is why UN marks are
often indicating a specific gravity of 1.4 or 1.5 when vented compared with 1.8 or
1.9 non-vented. Taking these factors into account with those described above it
can be seen that "paneling" can occur at lower than tested top load.

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This paper was prepared and endorsed by the Plastic Drum Institute (PDI)

The Plastic Drum Institute (PDI) is a trade association, which represents manufacturers of
industrial plastic containers, polyethylene resin manufacturers, closure and ring
manufacturers, industrial container recyclers and equipment manufacturers in North America.

TERMS OF USE: By using this document, you signify acceptance of all terms, conditions and notices
posted on PDI's website, www.plasticdrum.org, which are incorporated by reference herein. Please note, in
particular, that all materials prepared or endorsed by PDI are for general informational purposes only and
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